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TABLE OF CONTENTS
Table of Contents 2General Information 3Contents of Package
4Warranty 4Safety Considerations 5Earth Grounding of Equipment
5Warning Labels 5Training 6Equipment Handling 6Receiving and Damage
Claims 6Storage 7Long Term Storage 7Removal from Storage
7Construction 8System Descrip tion 8Theory of Operation: The Eddy
Current Drive 8Theory of Operation: Closed Loop Control Systems
9
Figure 1. Typical Closed Loop Control System 9Mounti ng the
DSI-700 Controller 10
Figure 2. DSI-700 Mount ing Dimensions 10Terminal Connections
11
Figur e 3. DSI-700 Terminal Layout 11Figure 4. DSI-700 Test
Point s and Adjustm ents 12
DSI-700 Power Input Jumper Setting s 13Prelimi nary Setup (No
Power Appl ied to DSI-700) 14Other Jumper Options 14
Accelerat ion Ti me 14Deceleration Time 14Max Speed Range
14Torque Limit 14
Torque Limit Range 15Table 1. Current Transfo rmer Turns and
Wire Size 15Table 2. Typical Motor Full Load Current s
16Determining the Maximum Current 17
Figure 5. Typical DSI-700 Connecti on Diagram 19DSI-700
Controller Set-up Adjustments 20
Factory Calibration s 20Factory Setting s 20User Adjust ments
21
Specifications 22Other DSI-700 Features 23
Output Signals 23Input Signals 23Inhibit Input 24External
Current Limit Control 24Selectable Output Voltage Range 24
Figure 6. Functi onal Schematic Diagram 25Trouble Shooting
26
If the Drive Will Not Run 26If the Drive Runs Only at Full Speed
27If the Drive Hunts (Speed Will Not Stabili ze) 28
Renewal Parts and Service 29
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GENERAL INFORMATION
Introduction
This instruction manual contains the necessary information
required for the normal installation,operation, and maintenance of
the Model DSI-700 eddy current controller. Please make it
available to all maintenance and operating personnel.
The DSI-700 is a quality, high performance controller capable of
providing excitation for theDynamatic Ajusto-Spede eddy current
drives, as well as those manufactured by others. The DSI-700 may be
used with drives ranging from the fractional hp FAS line of drives
from 1/4- to 1.5-Hp,the complete AS line of integral motor-clutch
drives from 1- through 40-Hp, as well as the full lineof AT drives
through 200-Hp.
Instructions provided in this manual are arranged in their
normal order of use. Beginning with
general information on warranty, safety, training, equipment
handling, receiving and damageclaims, and storage, it gives brief
information about system description, specifications,
installation,start-up and various adjustments, maintenance and
trouble shooting. These instructions do notcover or describe any
modification that may be used with the controller, but they do
address eachand every adjustment and/or user-accessible function of
the controller. In the case of special ormodified controllers, use
this instruction manual in conjunction with any specific schematic,
printsor instructions supplied with your specific controller.
Special drawings shall take precedence overprinted instruction
material if a difference in content occurs.
While every effort has been made to provide a complete and
accurate manual, there is nosubstitute for trained, qualified
personnel to handle unusual situations. If any questions
ariseregarding operation or maintenance of this controller, please
refer them immediately to:
Custom er Service DepartmentDrive Source International, Inc.
7900 Durand AvenueStur tevant , WI 53177
Phone is (262) 554-7977FAX is (262) 554-7041
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Please make these instructions available to your operating and
maintenance personnel. Trainingprograms are an essential part of
safe and correct operation, and provide the know-how necessaryto
obtain top performance from your equipment. The technical staff at
Drive SourceInternational, Inc. recognizes this fact and is capable
of conducting training schools to educateyour plant personnel in
safe maintenance and operating procedures. Special training
schoolsstructured around your specific equipment can be arranged in
our plant or at your facility. Thesemay be scheduled by calling our
Customer Service Department. There is a nominal fee for
thisservice.
Equipment Handling
The DSI-700 controller weighs just over a pound and can be hand
carried safely. Do not drop orsubject the controller to shock or
vibration. Do not stack heavy material on the controller.
Theprinted circuit board, although ruggedly built, consists of
various components, some of which aredelicate and susceptible to
damage. The circuit board does contain CMOS components that maybe
susceptible to electrostatic damage. The controller should be kept
in the protective anti-staticpackaging until it is needed, and then
it should be handled at an anti-static work station, usingpersonnel
grounding straps and proper attire.
Receiving and Damage Claims
The DSI-700 controller has been operated and tested at the
factory prior to shipment. Specifictest procedures are followed to
assure the quality of your controller. Carrier-approved packing
methods assure safe shipment to your plant. Shipment is made
F.O.B. from our factory, with thecarrier assuming responsibility
for your unit. Therefore, it is essential that the shipment
becarefully inspected upon delivery to ensure that no items were
lost or that no damage occurred intransit. Loss or damage is
covered by the carrier, not by the product warranty. File a
claimimmediately with the carrier if any damage or loss is found.
If you require assistance in settlingyour claim with the carrier,
contact your Drive Source International representative. You will
needthe unit model number, serial number, and the purchase order
number for identification purposes.
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Construction
The DSI-700 is offered in an Original Equipment Manufacturer
(O.E.M.) package as a basic,central control unit to provide maximum
performance at the lowest price. It features singlecircuit board
construction with integral heat dissipater for the power
components. Only thetopside of the circuit board is populated,
using hybrid surface-mount as well as through-holetechnologies.
System Description
The DSI-700 is a solid-state controller compatible with a
variety of eddy-current adjustable speeddrives. This versatile
controller features the simple set-up of analog circuitry, and
employs thetime-tested surge and overload capability of the
thyristor-controlled power converter. Each unit isfully tested and
adjusted at the factory for nominal performance. This allows the
user to connectand operate the controller, out of the box, with a
minimum of adjustments.
Theory of Operation: The Eddy Current Drive
In the basic form, the eddy current drive consists of an AC
motor and an electrically controlledmagnetic clutch. The eddy
current clutch is composed of an input drum which is driven by
themotor at constant speed, and an output rotor, usually positioned
concentrically within the drum.Both members are constructed of
magnetically soft iron (low carbon steel), supported by balland/or
roller bearings, and free to rotate independently of each other,
separated by a small airgap. Control is imparted by means of an
electrical field coil, which is strategically positioned toallow
magnetic coupling between the input and output members of the
clutch. The eddy current
brake operates in a similar manner, except that the “drum”
member remains stationary.
In a motor, a time-variant magnetic field is generated in the
air gap at the poles by means of thecurrent flowing in the
windings, the field reversals being accomplished by an alternating
current inthe AC motor, or by means of brushes and the
electro-mechanical commutator in the DC motor.
The eddy current clutch acts as a rotating transformer similar
to a motor. In the eddy currentclutch, a static DC current produces
a magnetic field in the air gap, coupling the rotating inputdrum
and the output rotor. The pole geometry of the coupled output
member imprints a pattern ofalternating magnetic domains on the
drum. Flux reversals are established in the field by virtue ofthe
speed differential between the input and output members, generating
eddy currents. A currentof high magnitude is generated in the
rotating drum, which appears as a single turn secondarywinding.
This current regenerates the magnetic field, producing a radial
coupling force, draggingthe output member along. The torque
developed herein is essentially proportional to the
coilcurrent.
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Theory of Operation: Closed Loop Control Systems
A typical closed loop control system is depicted below in Figure
1.
Figure 2 Typical Feedback Control System
Figure 1 Typical Closed Loop Control System
This control system employs closed-loop feedback control
techniques to linearize and stabilize theperformance
characteristics of the machine. In the basic speed control system,
the speedreference signal is the COMMAND that drives a high gain
summing amplifier that in turn,provides the drive current to the
clutch field coil. This clutch current produces a magnetic
couplingbetween the constantly rotating drum and the output rotor.
The resulting torque causes the outputshaft to rotate; this output
speed being the CONTROLLED QUANTITY .
A tachometer generator is internally coupled to the output
shaft, and produces an AC voltageproportional to the speed, at a
frequency that is also proportional to the output speed. This
ACsignal is a MEASURE OF THE CONTROLLED QUANTITY , and is fed back
to the summing
amplifier where it is compared to the COMMAND signal. The
difference between the speedreference and the feedback signal is
the ERROR signal which causes the clutch current toincrease if the
output speed is lower than, or decrease if the output speed is
higher than the speedset reference signal.
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Not shown in Figure 1 is an adjustable inner clutch current
feedback loop that is employed in theDSI-700 for improving or
tuning the response of a wide variety of machine
characteristics.
In the DSI-700 , the frequency of the tach-generator is
converted to a DC signal for comparisonwith the speed reference. By
using the tach frequency rather than the voltage, the
non-linearityintroduced by the diode bridge rectifier is
eliminated. Also, since the conversion is handled at ahigher
frequency, less filtering is required in this scheme, providing
better phase margin for controlstability. Frequency feedback also
improves control performance by eliminating the differences
orvariations in the generator output voltage from machine to
machine.
Mounting the DSI-700 Controller
The front cover page shows the DSI-700 in the normal vertical
mounting plane. The board may berotated ninety degrees, or mounted
in the horizontal plane without impairing the natural
convectioncooling characteristics. Care should be taken, however,
to provide sufficient headroom above thePCB that might impede
proper air flow, or to avoid mounting the controller PCB above
other heat-
generating components. Adequate ventilation inside the control
panel enclosure will preventpremature failure due to heat
build-up.
The controller may be mounted to a substrate panel using four
(4) standoff insulators and screws(provided). Mounting dimensions
are shown below in Figure 2.
Figure 2 DSI-700 Mounting Dimensions
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Terminal Connections
The DSI-700 controller is supplied with a quick
connect-disconnect terminal block. Theterminal designations are
given below in Figure 3.
The DSI-700 was designed to be directly interchangeable with
controllers manufactured byothers, such as the Torspec 5001TCP the
Tasc 1268P and the Tasc 1274P. The terminal pin-out and the
mounting dimensions are identical, although the DSI-700 has a
smaller overallfootprint, and provision has been made for a current
transformer. Operating specifications andperformance are
similar.
Figure 3 DSI-700 Terminal Layout
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Figure 4, below, displays the location of the potentiometer
adjustments, test points, and other
components to assist the operator in setup or trouble
shooting.
Figure 4 DSI-700Test Points and Adjustments
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DSI-700 POWER INPUT JUMPER SETTINGS
Line Input Voltage
FAILURE TO CHECK THE SUPPLY VOLTAGE MAINS AND CONFIGURE THE
CONTROLFOR PROPER INPUT AND OUTPUT VOLTAGE MAY RESULT IN IMPROPER
OPERATIONOR DAMAGE TO THE CONTROLLER AND/OR MACHINE.
The DSI-700 may be set up for 120- or 240-VAC input. The
controller is configured for the properinput voltages with two (2)
header shunts (jumpers) at JP5 . The output voltage is a function
of theline input voltage. The jumper configuration is shown on the
circuit board at the location of JP5 inthe lower left hand
corner.
With the shunts in the 120V position, the input voltage is
120-VAC with a resulting output of 0- to45-volts DC or 0- to
90-volts DC, the range being selected by the jumper at header JP3 .
Connectthe high line to terminal A2 and the neutral line to
terminal N1 . The maximum coil voltage may bereduced to values
below 90-V by adjusting the CUR LIMIT potentiometer, P9 for the
desiredvoltage limit. Please see the section on controller set-up
and adjustment beginning on page 20.
With the shunts in the 240V position, the input voltage is
240-VAC with a resulting output of 0- to90-volts DC or 0- to
180-volts DC, depending on the selection of jumper JP3. Connect the
240Vlines to terminals A1 and A2 . DO NOT USE TERMINAL “ N1” WHEN
USING THE 240-VOLTINPUT. The maximum coil voltage may be reduced to
values below 180-V by adjusting the CURLIMIT potentiometer, P9 for
the desired voltage limit. Please see the section on controller
set-upand adjustment beginning on page 20.
Care must be exercised in sizing the clutch coil to the
controller. When using the CUR LIMIT pot,P9, for operation below
the rated output voltage, the user is cautioned to insure that the
maximumcontroller output rating of 5.6-amps DC is never exceeded.
Failure to follow this advice may leadto blown fuses or permanent
damage to the controller.
ALL DSI-700 CONTROLLERS ARE CONFIGURED AND TESTED AT THE
FACTORYFOR 120-VAC INPUT AND 90-VDC OUTPUT
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PRELIMINARY SETUP(No Power Appl ied to DSI-700)
OTHER JUMPER OPTIONS
Acceleration Time:
DSI-700 has two (2) acceleration ranges. The 10-second range is
selected when the headershunt is applied in the 10S (right-hand)
position at header JP2 , and the 100-second range isselected when
the shunt is applied in the 100S (left-hand) position. The speed
input signalconditioning may be defeated by removing the range
shunt entirely. This may be advantageouswhen operating in the
remote signal mode (Terminal A15) where the response of the drive
mustfollow the input signal directly without the delay of an
acceleration circuit.
Deceleration Time:
Controlled deceleration times are provided by header, JP1 . Log
deceleration time is achieved at
the same rate as the acceleration time with the header shunt in
the A (left-hand) position atheader, JP1 . Placing the shunt in the
B (right-hand) position at JP1 provides for a quickdeceleration
time by rapidly discharging the acceleration capacitors.
Max Speed Range:
Header JP6 sets the max speed range of the drive. Select the LO
(upper) speed position for4-pole motors (1800-rpm) or the HI
(lower) speed position for 2-pole motors (3600-rpm).
Torque Limit: (Separate Current Transformer Required)
A motor protection circuit is provided in the DSI-700 controller
to limit the torque produced by themotor by monitoring the motor
line current. This feature is useful in metal stamping
pressapplications where the large inertia of the flywheel would
stall the motor during start-up. TorqueLimit is accomplished by
means of an external current transformer (purchased separately)
that isconnected to the “ CT” terminals on the input terminal
block. This signal is conditioned andcompared to the internal
reference as set by the TORQUE LIMIT pot, P14 . The on-board
torquelimit reference is selected by placing the header shunt in
the A (upper) position at header, JP7 .
Although the B (lower) position at header JP7 provides for an
external potentiometer at the inputterminal block, this external
reference controls the maximum clutch coil current or
voltagesimilar to the on-board CUR LIMIT pot, P9 , not the motor
current. It is essentially a remote, off-board CUR LIMIT
adjustment. Please see “Other DSI-700 Features” beginning on page
23.
Motor protection is provided only by us ing the on-board Torque
Limit reference pot, P14with the JP7 jumper in the UPPER position
.
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Torque Limit Range:
The DSI-700 provides motor protection by limiting the current to
the clutch by monitoring the motorcurrent. As the board is
configured, motor currents up to 150-Amperes can be controlled. It
maybe necessary to pass the motor lead through the center of the
current transformer more than onceto achieve the proper protection
on smaller motors. Use the following table to determine thenumber
of turns through the center of the current transformer for the
corresponding maximummotor amps. Note: A “turn” is defined as a
pass through the hole in the transformer, such that asingle wire
passing once through the center of the transformer is one turn. A
wire passingthrough, looping once around the outside of the
transformer and through the center again is twoturns. The following
data is valid when using current transformer part number 15-203-3
.
TABLE NO. 1
CURRENT TRANSFORMER PRIMARY TURNS AND WIRE SIZE
MAX MAX AMPS MAX AMPS # OF TURNSWIRE SIZE CONTINUOUS OVERLOAD
THROUGH CT
4 95 50 – 150 16 75 25 – 75 28 50 16 – 50 3
10 38 12 – 38 414 25 8 – 25 616 18 6 – 18 8
16 ** 7.1 ** 2.3 – 7.1 ** 1**16 ** 3.5 ** 1.2 – 3.5 ** 2 **16 **
2.3 ** 0.75 – 2.3 ** 3 **16 ** 1.8 ** 0.6 – 1.8 ** 4 **
NOTE: * Wire size shown is for 90-degree, C insulation at max.
continuous current.
** For maximum current ratings of 7.1-Amperes or less, the USER
MUSTREMOVE the 2.7-ohm resistor, R-81A, by cutt ing the resis tor
leads closeto the circui t board. This resistor is located directly
above the right-handend of the 22-pin connector. Discard the
resistor.
NOTE: If the maximum required overload motor current exceeds
150-amperes, pleasecontact the factory for alternate current tr
ansformer assemblies.
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The following table provides approximate motor full-load line
currents with respect to inputvoltage for a variety of drives which
may be used with this controller. This information may beuseful
when applying the current transformer for the TORQUE LIMIT
function.
TABLE NO. 2
TYPICAL MOTOR FULL LOAD CURRENTS
Three Phase AC Induction, Squirrel Cage, Wound Rotor
DETERMINING THE MAXIMUM CURRENT
HP 208-V 230-V 460-V 575-V
0.50 HP 2.0 A 1.7 A 0.9 A 0.8 A
0.75 HP 2.8 A 2.9 A 1.5 A 1.1 A
1.0 HP 3.2 A 3.6 A 1.8 A 1.4 A1.5 HP 5.6 A 4.9 A 2.5 A 2.1 A
2 HP 7.4 A 6.4 A 3.2 A 2.7 A
3 HP 10.8 A 9.4 A 4.7 A 3.9 A
5 HP 16.6 A 14.4 A 7.2 A 5.8 A
7.5 HP 25 A 22 A 11 A 9 A
10 HP 31 A 27 A 14 A 11 A
15 HP 45 A 39 A 20 A 16 A
20 HP 59 A 51 A 26 A 21 A25 HP 75 A 65 A 33 A 26 A
30 HP 87 A 76 A 38 A 30 A
40 HP 116 A 101 A 51 A 40 A
50 HP 150 A 124 A 62 A 50 A
60 HP 174 A 152 A 75 A 60 A
75 HP 225 A 195 A 92 A 73 A
100 HP 300 A 247 A 118 A 95 A
125 HP - 293 A 147 A 117 A
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Since the motor amps can be adjusted down to almost zero, this
taskcould also have been accomplished with only two turns through
thecurrent transformer. In that case:
Maximum Current = 150 / T = 150 / 2 = 75.0-amps
This corresponds to (75 / 26.6 = 2.82) or 282% of rated amps.
This willwork just as well, but care must be taken to properly
adjust the TorqueLimit pot , P14 , down so that the motor current
begins to limit at 26.6-amperes. A better choice would be three or
four turns.
Example 2: Given: A motor with no nameplate, although it is
known that the motor iswound for 460-volts, and is rated at 75-hp
at 1750-rpm.
This drive is to be used on a metal stamping press, operating
from the460-volt AC mains. It is determined that the acceleration
time to get theflywheel up to speed is about seven seconds if the
motor can be allowedto operate at 50% overload, or 150% of rated
full load current. Since thepress is started only two or three
times a day, the motor should be able tohandle this overload for
the short duty cycle without degradation.
Table 2, indicates that a 75-hp motor operating at 460-VAC will
have a fullload current rating of 92-amperes. The maximum overload
current will be150% or (1.5)(92) = 138-amperes. Table 1 indicates
that one turn of #4wire through the current transformer can carry
the continuous 92-full loadamps, and that 138-amps in overload can
also be accommodated. Thiswill result in:
Maximum Current = 150 / T = 150 / 1 = 150 amps
which is (150 / 92 = 1.63) or 163% rated motor current. Use the
Torque Limit pot, P14 , to adjust the current limit point up or
down to 138-amps.
In a case such as this, the acceleration time to bring the
flywheel up tospeed is not critical, so the Torque Limit could be
set lower, perhaps to125%, at the expense of increasing the
acceleration time by only anothersecond or two.
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Figure 5, below, demonstrates typical connections for the
various DSI-700 functions.
Figure 5 Typical DSI-700 Connect ion Diagram
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= = = PLEASE NOTE = = =
Before proceeding
Determine proper motor rotation by momentarily “bumping” the
motor with NO power being applied
to the DSI-700 controller. If the direction of rotation is
incorrect , disconnect the power to the motorand interchange any
two motor power supply leads to reverse the motor direction.
DSI – 700 CONTROLLER SET-UP ADJUSTMENT(WITH POWER APPLIED TO THE
CONTROLLER)
All DSI-700 controllers are operated at the factory on a fully
instrumented test stand employinga typical motor/clutch drive with
an electrically adjustable load. The controllers are adjustedduring
final test, and can generally be operated, out of the box, without
further adjustment.Different operating modes or special
applications may require adjustment of some parameters.
Factory Calibrations
The following adjustments have been calibrated at the factory,
and should require nofurther adjustment:
POT DESIGNATION FUNCTION FACTORY SETTING
P10 4-mA SET Speed current signal output offset AS REQUIREDP11
20-mA SET Speed current signal output span AS REQUIRED
Factory Settings
The following adjustments have been set at the factory, but may
require readjustment toachieve proper response or stability in some
instances:
POT DESIGNATION FUNCTION FACTORY SETTING
P1 GAIN Speed loop gain control 0% CWP2 DIF Speed differential
gain control 100% CW
P4 CUR DAMP Current loop gain control 50% CWP6 INT Speed
integral gain control 25% CWP9 CUR LIMIT Clutch coil current
(voltage) limit control 100% CW
User Adjustments
The following adjustments have been set at the factory, but
specifi c machine condit ionsmay require readjustment to achieve
proper or desired operation:
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POT DESIGNATION FUNCTION .
P7 Accel Rate This adjustment provides for setting the
acceleration to a specificrate within the 10-second or 100-second
range as set by the
jumper at header JP2 . Turning the adjustment CW increases
therate (faster), while a CCW setting will decrease the rate,
slowingdown the acceleration time. This adjustment is f actory set
at100% CW for highest acceleration rate.
P8 Min. Speed Turn the external main drive speed pot to 0% (full
CCW). Set theMin. Speed pot, P8 , for zero volts on the clutch coil
or no shaftrotation. Alternately, the Min. Speed may be set to a
higher speedif the application so requires. This adjustment is f
actory set asrequired for no shaft rotation.
When using the 4- to 20-milliamp remote signal input, the
4-maminimum loop current will have to be offset. Min. Speed pot, P8
,should be adjusted to produce the required minimum speed.
P12 Max. Speed Turn the external main drive speed pot to 100%
(full CW). Adjustthe Max. Speed pot, P12 , to the desired maximum
speed. It maybe necessary to repeat adjustments of P8 and P12 as
they tend tointeract. This adjustment is factory set as
required.
P13 Meter Cal. This adjustment allows the user to calibrate the
controls DCanalog output to any scale from 0 – 1VDC to 0 – 10VDC
for anyspeed output required. Using a tachometer or other
speedmeasuring device, observe the speed and adjust the P13 to
thedesired reading.
P14 TORQUE LIMIT This adjustment is functional only when an
external currenttransformer is used with the DSI-700 controller.
The coupledtorque can be controlled to almost zero by turning P14
fully CCW.Consequently, turning the pot fully CW will allow the
clutch toproduce higher torque, allowing the motor to operate at
full load orbeyond. Adjust the TORQUE LIMIT pot, P14 , for the
desiredlimiting point by observing the motor line current with a
clamp-onammeter.
JP3 VOLTAGE This jumper function enables the user to select the
output voltageRANGE range of the controller. Jumper JP3 is in the
“90V” position when
the DSI-700 is shipped from the factory. Please see “
OTHERFEATURES” on page 24 for details.
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SPECIFICATIONS
Physical Details
Width: 7.36 inches (187 millimeters)Height: 5.79 inches (147
millimeters)
Depth: 1.18 inches (30 millimeters)Net Weight: 1.00 pounds (454
grams)
Input Characteristics
Supply Voltage 120-VAC or 240-VAC, +/-10%Line Frequency
50/60-HzTach Generator Frequency 10 - 720 HzTach Generator Voltage
3 volts, peak-to-peak minimum
Output Characteristics
Output Voltage @ 115-VAC Input 0-45 VDC, 0-90 VDC,
SelectableOutput Voltage @ 230-VAC Input 0-90 VDC, 0-180 VDC,
SelectableOutput Current 5.6 Amps, Full Voltage Output
4.0 Amps, Half Voltage outputSpeed output signal (voltage)
0-10VDCSpeed output signal (current) 4-20MA (500 ohms max.
resistance)
Regulation
Line Voltage Change: 10% 0.1% @ 1600-rpm (1.5-rpm typical)Load
Change: 25% - 100% 1.0% @ 1600-rpm (15-rpm typical)
Run Speed Potentiometer
Standard 2 Watt Molded Carbon Potentiometer 1000 - 5000 ohms
Temperature
Ambient Air, Operating 32 to 104-degrees, F. (0 to 40-degrees,
C.) Ambient Air, Storage, Non-Condensing -4 to 158-degrees, F. (-20
to 70-degrees, C.)
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OTHER DSI-700 FEATURES
OUTPUT SIGNALS
0-1VDC min to 0-10 VDC max (10 ma max. load)
This isolated voltage output signal is available at terminals
A13(+) and A12(-) . It can beused to drive a speed indicator or
used as a “follower” reference signal to control a“slave” drive.
Adjustment is provided by the Meter Cal. (P13) pot.
4ma-20ma DC (500 ohm or less resistance)
This isolated current output signal is available at terminals
A21(+) and A22(-). It can beused to drive a 4-20 ma DC speed
indicator or used as a “follower” signal to control a“slave” drive.
Adjustment of the 4-ma offset is affected by the 4-mA (P10) pot,
while the20-ma span adjustment is made using the 20-mA (P11)
pot.
Frequency Output
This isolated output signal corresponds to the tachometer
generator feedback. It is abuffered square wave which may be used
for driving time-based speed indicators, or adigital reference
follower for a slave drive.
INPUT SIGNALS
Alternate speed reference signals can be used to control the
DSI-700 controller in placeof a speed setting pot. This would
typically be used when the DSI-700 is required to
“follow” another drive or process controller. To use these input
signals, the jumper(shunt) at header, JP1, should be in the (A)
position (no connection), and the jumper(shunt) at header, JP2 ,
should be removed altogether (no capacitor selected).
0-10 VDC SIGNAL
Connect this remote signal to terminals A15 (+) and A12 (-).
4-20 MA DC CURRENT SIGNAL
Again, connect this remote signal to terminals A15 (+) and A12
(-). Also, connect a jumper between terminals A15 and A16 to
provide the 20-ma load resistor.
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OTHER FEATURES
Inhibit Input
An inhibit input is provided at terminal A14 for the purpose of
bringing the controller to a“stop” condition while maintaining
power to the control. Tying the INHIBIT input atterminal A14 to the
+10 VDC reference source available at terminal A7 or A10
willactivate the inhibit function by discharging the acceleration
capacitors in the referencecircuit, and clamping the output of the
phase shifter. Removing the reference voltage tothe INHIBIT input
will cause the inhibit function to turn off, returning the
controller towhat ever normal “run” condition existed before the
inhibit was invoked.
External Current Limit Contro l
On page 13, the function of the CUR LIMIT adjustment, P9 , was
described as a “voltagelimit” control. This is accomplished by
essentially clamping the output of the phaseshifter such that the
output voltage of the controller no longer increases for any
furtherincrease in the input reference voltage signal.
This function can be achieved with an external control
potentiometer connected toterminals A5, A6, and A7 as shown in
Figure 3 on Page 11, as well as Figure 5 onpage 19. The jumper at
header, JP7 , must be in the (lower) B position as described onpage
14.
The operating range on this adjustment is “touchy”, full control
being achieved over asmall range of the pot. If this remote
function is desired, better control can be achievedwith the use of
range limiting resistors in both the top and bottom legs of the
control pot.
Selectable Output Vol tage Range
A header, JP3, is provided with a jumper to provide for
selecting the output voltagerange of 0- to 45-VDC or 0- to 90-VDC
when operating at 120-VAC input. This isaccomplished by modifying
the power converter to provide only half the power in thelower
range, rather than limiting the phase-up angle. This power
reduction method ispreferred because the system gain remains
constant, preserving the stability of thedrive. When operating at
240-VAC input, the jumper may be used to select 0-to 90-VDC or 0-
to 180-VDC output.
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FUNCTIONAL SCHEMATIC DIAGRAM
TO FACILITATE JUMPER PLACEMENT AND PARAMETER ADJUSTMENTSBELOW IS
FUNTIONAL SCHEMATIC DIAGRAM.
Figure 6. Functional Schematic Diagram
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TROUBLE SHOOTING
Component failure or other problems are always possible with
circuit boards. This section of themanual is provided to assist in
finding the fault and making repairs. Our design philosophy isbased
on assembly replacement. Trying to repair a failed printed circuit
board is not economicalwhen the cost of labor and down time is
compared with the cost of PCB replacement. Therefore,this manual
limits trouble shooting to sub-assembly level. Only qualified
personnel acquainted withsafety procedures should service this
equipment.
1. Check that all plugs and jumpers are in the proper position
before turning power “ON”.
2. Check that the fuses are in place and are intact.
3. Check that the clutch and feedback generator leads are
connected properly to thecontroller. Refer to the connection
diagrams on page 11 or 19. The mechanical drive andthe DSI-700
control panel should be connected to earth ground. (Refer to
EquipmentGrounding section of this instruction manual).
IF THE DRIVE WILL NOT RUN
1. Check the incoming power supply, 120VAC or 240VAC, with a
voltmeter to verify thatpower is being supplied to the motor and
DSI-700 controller.
2. Blowing of fuses may occur during any short circuit or
overload condition. With the motorand controller disconnected from
the power source, check fuses F1 and F2 (8 amp) and F3(500 ma). If
fuses are open, replace the fuses with the same type and value.
Re-applypower to the motor and controller.
3. If a fuse blows on a cold start, there may be a short or
ground in the clutch coil or leadwires. Disconnect both leads at
the controller terminal strip (A3 and A4), and measure
theresistance of the coil and resistance of the coil to ground.
Check the clutch nameplate orinstruction manual for the proper coil
resistance. In general, the coil resistance should lie ina range of
16- to 100-ohms. Resistance to ground should be about 20 megohms.
Whenusing a megger, make sure both coil leads are disconnected from
the controller. If a shortor open coil is detected, machine repair
will be necessary. Please contact theDSI/Dynamatic factory for
repair assistance.
4. Disconnect the run speed pot lead from terminal A10. Connect
a DC voltmeter to terminals A10(+) and A12(-). With power applied
to the DSI-700 controller, a reading ofapproximately 10 VDC should
be observed. If the voltage differs from 10 VDC
significantly,replace the DSI-700 controller. Otherwise, reconnect
the wire to terminal A10.
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5. Connect a DC voltmeter between terminals A11(+) and A12(-).
With power applied to the
controller, rotate the speed setting potentiometer from “0” to
“100%”, observing that thespeed reference voltage follows between
“0” and “+10” volts, DC. Refer to page 11 or 19for the proper
connections.
6. Check the CUR LIMIT pot, P9 . Normal setting for this
adjustment is 100% CW. Althoughthe control operates at reduced
output at lower settings, the controller will not run at all ifthis
adjustment is at or nearly at the fully CCW setting.
IF THE DRIVE RUNS ONLY AT FULL SPEED
7. Connect a DC voltmeter between terminals A11 (+) and A12 (-).
With power applied to thecontroller, rotate the speed setting
potentiometer from “0” to “100%”, observing that thespeed reference
voltage follows between “0” and “+10” volts, DC. Refer to page 11
or 19for the proper connections.
8. Check the position of the jumper at header JP6 . This should
be in the LO position for 4-pole (1800-rpm) motors, and in the HI
position for 2-pole (3600-rpm ) motors.
9. Check the setting of the MAX SPEED pot, P12 . Try adjusting
the pot down (CCW) toadjust the drive speed.
10. Check for a proper tachometer feedback signal by checking
the FREQ OUT signal at TP5 or terminals A19 and A12 for a square
wave output proportional to the speed. The tach
generator input may also be checked by reading at least 5-volts
peak-to-peak (AC) at thegenerator input terminals, A8 and A9 . If a
zero or near zero voltage reading is observed,the problem may be a
faulty tach generator in the mechanical drive. Check for broken
orshorted connections between the clutch and controller.
11. Check the control output voltage between A3 and A4 . If
proper tach feedback wasobserved above in step 10, AND the
controller output is zero or near zero, the clutch maybe physically
locked up, and the mechanical unit should be checked for proper
operation.
IF THE DRIVE HUNTS (SPEED WILL NOT STABILIZE)
12. Check the settings for adjustments P1, P2, P4, and P6 as
given on page 20 for factorysettings. One at a time, try
readjusting each of these pots in an effort to affect animprovement
in stability. The following suggestions can be offered:
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